Weatherproof decorator cover with positive indicator

ABSTRACT

A weatherproof switch cover includes a base plate, a rocker arm provided in the base plate and movable between a first position and a second position and a membrane provided below the rocker arm, the membrane providing a weatherproof seal.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of co-pending application Ser. No.16/508,672, filed Jul. 11, 2019, which is a continuation of applicationSer. No. 15/340,086, filed Nov. 1, 2016, which claims priority to U.S.Provisional Application Ser. No. 62/249,994 filed Nov. 3, 2015 each ofwhich are incorporated herein by reference in their entirety.

BACKGROUND Field

The present disclosure relates to switch covers and, more particularly,to weatherproof decorator switch covers with positive indicators.

Description of the Related Art

Weatherproof toggle switches are often used in damp or wet environments.Various ways exist for providing a weatherproof toggle switch. One wayis to provide a switch designed and manufactured to include a sealedconfiguration for preventing condensation or water from entering theswitch. Another way is to provide a weatherproof switch plate coverwhich includes a sealed membrane that covers the forwardly projectingtoggle lever. When used in conjunction with the weatherproof switchplate cover, a standard interior toggle switch can be used in damp orwet environments.

Interior wall switches have evolved from simple on/off toggle switchesto more attractive décor type switches. Décor type switches includedecorator rocker style switches.

Weatherproof switch plate covers exist for use with rocker styleswitches. However, these covers generally consist of a flat rubbermembrane that covers the entire switch. One downside of these covers isthat it is not possible to visually determine whether the switch is inthe on or off position.

SUMMARY

A weatherproof cover includes a base plate, a rocker arm provided in thebase plate and movable between a first position and a second positionand a membrane provided below the rocker arm, the membrane providing aweatherproof seal.

A weatherproof cover kit includes a rocker switch adapted for switchingelectrical power on and off, a weatherproof electrical box in which therocker switch is to be mounted and a weatherproof switch cover adaptedfor covering the rocker switch and mountable to the weatherproofelectrical box. The weatherproof switch cover includes a base plate, arocker arm provided in the base plate and movable between a firstposition and a second position, and a membrane provided below the rockerarm, the membrane providing a weatherproof seal.

A multi-gang weatherproof cover includes a base plate, at least tworocker arms provided in the base plate, each rocker arm movable betweena first position and a second position and a membrane provided below theat least two rocker arms, the membrane providing a weatherproof seal.

A multi-gang weatherproof cover includes a base plate, a rocker armprovided in the base plate and movable between a first position and asecond position, a flip cover pivotally mounted to the base plate andproviding a weatherproof seal and a membrane provided below the rockerarm, the membrane providing a weatherproof seal.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the present disclosure and many of theattendant advantages thereof will be readily obtained as the samebecomes better understood by reference to the following detaileddescription when considered in connection with the accompanyingdrawings, wherein:

FIG. 1 is a top perspective view of a representative weatherproof switchcover according to an illustrative embodiment of the present disclosure;

FIG. 2 is a bottom perspective view of the representative weatherproofswitch cover according to an illustrative embodiment of the presentdisclosure;

FIG. 3 is side perspective view of a representative weatherproof switchcover according to an illustrative embodiment of the present disclosureand a utility box housing a decorator type rocker style switch;

FIG. 4 is an exploded view of a weatherproof switch cover according toan illustrative embodiment of the present disclosure;

FIGS. 5A and 5B are cross-sectional side views showing how theweatherproof switch cover interacts with a decorator type rocker styleswitch according to an illustrative embodiment of the presentdisclosure;

FIG. 6 is a perspective view of a multi-gang weatherproof switch coverfor covering two decorator type rocker style switches according to anillustrative embodiment of the present disclosure;

FIG. 7 is a perspective view of a multi-gang weatherproof switch coverfor covering a decorator type rocker style switch and a duplex outletaccording to an illustrative embodiment of the present disclosure.

DETAILED DESCRIPTION

Illustrative embodiments of the present disclosure may be provided asimprovements to weatherproof switch covers. For example, a weatherproofswitch cover according to an embodiment of the present disclosure allowsan decorator type rocker switch to be used in wet or damp environments.

Illustrative embodiments of the present disclosure provide multi-gangweatherproof covers for covering two or more decorator type rockerswitches and/or a decorator type rocket switch and a duplex outlet.

According to an embodiment of the present disclosure, a weatherproofswitch cover includes a rocker switch mechanism that provides positivetactile feedback to a user when the user moves the switch between the onand off positions.

In certain illustrative embodiments described herein, one or morecomponents of the weatherproof switch cover may be constructed frommetal (e.g., stamped steel, spring steel), plastic (e.g., polycarbonateor nylon) or a combination of such materials. Alternatively, steel,galvanized steel, brass, aluminum or other appropriate alloy may be usedfor the appropriate components. Of course, other types of materials suchas other types of plastics, composites, etc. may be used as desired andwhere appropriate.

In certain embodiments of the present disclosure, a weatherproof switchcover as disclosed herein is mounted to a weatherproof electrical box inwhich a decorator type rocker switch is provided. The weatherproofelectrical box may be a multi-gang box for housing one or more decoratortype rocker switches and/or one or more duplex outlets. The weatherproofswitch cover as disclosed herein may include one or more rocker armassemblies for covering one or more decorator type rocker switchesand/or one or more weatherproof flip covers for covering one or morestandard or decorator type duplex outlets.

A representative weatherproof switch cover according to an embodiment ofthe present disclosure is shown in FIGS. 1 and 2 and is referred togenerally as switch cover 100. According to this embodiment of thepresent disclosure, switch cover 100 includes a weatherproof rocker armassembly including a rocker arm 30 mounted to a base plate 10. The baseplate 10 includes a top wall 10 a, a bottom wall 10 b, a pair of sidewalls 10 c and 10 d and an exterior surface 10 e secured to orintegrally molded into the walls. The space within the walls 10 a-10 dand the exterior surface 10 e is an open interior area 10 f. A gasket 90may be removably provided on a back surface of the exterior surface 10 eof base plate 10 as will be described later below. Screws 24 extendthrough holes 12 provided in spacers 14 formed along the upper and lowerends of the base plate 10 such that the screws 24 align with screw holesin a yoke 130 of an electrical device, such as a decorator type rockerstyle switch 120, as will be described later below. A retainer 80 issecured to base plate 10 using fasteners 15. Retainer 80 holdscomponents of the rocker arm assembly in place. A sealing membrane 70which includes recessed nubs 72A, 72B provides a weatherproof seal aswill be described later below.

FIG. 3 depicts a single gang weatherproof electrical box 20 which may bemade of metal, plastic, etc. A decorator type rocker style switch 120 ispositioned in weatherproof electrical box 20 as shown. Electrical wiring(not shown) is run into electrical box 20 via one or more knockouts 121and is connected to decorator type rocker style switch 120 in the usualmanner. Decorator type rocker style switch 120 includes a rocker arm122. Generally, switch 120 is arranged such that rocker arm 122 ismovable between an “ON” position and an “OFF” position, where theposition shown is the “OFF” position. Rocker arm 122 would normally bepressed in area A in order to move rocker arm 122 to the “ON” position.Baseplate 10 of a weatherproof switch cover 100 according to anembodiment of the present disclosure, is positioned over rocker styleswitch 120 and is secured to weatherproof electrical box 20 such thatgasket 90 provides a weatherproof seal between baseplate 10 and an outeredge of weatherproof electrical box 20. Screws 24 which extend throughholes 12 in base plate 10 are aligned with screw holes 132 in the yoke130 of the decorator type rocker style switch 120 for securing baseplate 10 to weatherproof electrical box 20. As will be described in moredetail below, when weatherproof switch cover 100 is mounted toelectrical box 20, pressing rocker arm 30 in area A′ will cause switch120 to move to the “ON” position.

An exploded view of switch cover 100 is shown in FIG. 4. A weatherproofrocker arm assembly according to an embodiment of the present disclosureincludes rocker arm 30, plunger assembly 40, flipper 50, chassis 60,sealing membrane 70 and retainer 80. The rocker arm assembly is mountedto baseplate 10. As will be described later below with respect to FIG.5, flipper element 50 cooperates with the plunger assembly 40 forproviding a snap like action so that the user can feel the switchswitching thus providing tactile feedback to the user. Retainer 80 issecured to the back of base plate 10 to keep the rocker arm assemblytogether as described above. Sealing membrane 70 and gasket 90 may bemade of any suitable weatherproof sealing material including, forexample, rubber, neoprene, etc. The spring 42, finger 44, seen in FIG.5A, and flipper 50 may be made of suitable material such as steelincluding, for example, spring steel, etc. The other elements of switchcover 100 may be made from metal (e.g., stamped steel), plastic (e.g.,polycarbonate or nylon) or a combination of such materials. If the baseplate 10 and/or retainer 80 are made of metal, the retainer 80 may besecured to the base plate 10 with fasteners 15, seen in FIG. 2, whichmay include rivets, screws, a press fit, etc. If the base plate 10and/or retainer 80 are made of plastic, fasteners 15 may include sonicwelds, screws, rivets, etc. Rubber o-rings 22 slip onto screws 24 andprovide a weatherproof seal around orifices 12 in base plate 10.

A weatherproof switch cover 100 according to an embodiment of thepresent disclosure is shown in cross-section in FIGS. 5A and 5B mountedto a utility box 20. Rocker arm 122 is representative of a rocker arm ofa decorator type rocker style switch 120 that is mounted to box 20 belowweatherproof switch cover 100. For ease of description, the otherportions of switch 120 are not shown. Rocker arm 30 includes fingers32A, 32B located adjacent sealing membrane 70. Sealing membrane 70includes recessed nubs 72A, 72B. When rocker arm 30 is pressed alongsection B, rocker arm 30 moves into the position shown in FIG. 5A. Inthis position, finger 32B urges nub 72B into the rocker switch 122 belowsuch that the rocker switch below will be in, for example, the “OFF”position. When rocker arm 30 is pressed along section A, finger 32Aurges nub 72A into the rocker switch 122 below such that the rockerswitch 122 moves into, for example, the “ON” position shown in FIG. 5B.

Sealing membrane 70 includes a multi-tiered edge 74. Sealing membrane 70is sandwiched between carriage chassis 60 and retainer 80 such thatretainer 80 presses multi-tiered edge 74 into a correspondingly shapededge of carriage chassis 60, thus providing a weatherproof seal.

Flipper 50 rests on rocker nub 62 provided on carriage chassis 60.Spring 42 and finger 44 are movably provided in a recess 35 formed onthe back of rocker arm 30. Spring 42 urges finger 44 against flipper 50just above nub 62. As shown in FIG. 5A, flipper 50 is in a firstposition. When rocker arm 30 is pressed along section A, finger 44 movessuch that flipper 50 cams over in the opposite direction into the secondposition as shown in FIG. 5B. This arrangement provides a positivetactile feel when rocker arm 30 is moved between the “ON” and “OFF”positions.

FIG. 6 depicts a duplex weatherproof switch cover 200 according to anembodiment of the present disclosure. According to this embodiment, baseplate 202 is dimensioned to cover a 2 gang box 204 housing two decoratortype rocker switches 206, 208 as shown. The base plate 202 includes atop wall 202 a, a bottom wall 202 b, a pair of side walls 202 c and 202d and an exterior surface 202 e secured to or integrally molded into thewalls. The space within the walls 202 a-202 d and the exterior surface202 e is an open interior area 202 f. A gasket 214 is provided betweenbase plate 202 and box 204. One or more weatherproof rocker armassemblies including rocker arms 210 and 212 are mounted to base plate202. According to an embodiment of the present disclosure, the rockerarm assemblies are similar to the rocker arm assembly (e.g., singleswitch) described above with respect to FIG. 4. Of course, instead ofproviding separate rocker arm assemblies, the components of the rockerarm assembly may be designed and dimensioned for use with the 2 gangweatherproof switch cover 200. Screws 220 align with corresponding holes232 in the yoke 230 of the decorator type rocker style switches 206,208.

FIG. 7 depicts a duplex weatherproof switch/outlet cover 300 accordingto an embodiment of the present disclosure. According to thisembodiment, base plate 302 is dimensioned to cover a 2 gang box 304housing a decorator type rocker switch 306 and a duplex outlet 308,e.g., a decorator type duplex outlet, as shown. The base plate 302includes a top wall 302 a, a bottom wall 302 b, a pair of side walls 302c and 302 d and an exterior surface 302 e secured to or integrallymolded into the walls. The space within the walls 302 a-302 d and theexterior surface 302 e is an open interior area 302 f. A gasket 314 isprovided between base plate 302 and box 304. A weatherproof rocker armassembly including rocker arm 310 is mounted to base plate 302. Therocker arm assembly is similar to that described above with respect toFIG. 4. According to this embodiment, a flip cover 312 is pivotallymounted to base plate 302 via a spring biased hinge 332 and providesaccess to duplex outlet 308. Flip cover 312 includes a gasket 330providing a weatherproof seal. Screws 320 align with corresponding holes332 in the yoke 330 of the decorator type rocker style switches 306 andthe duplex outlet 308.

As shown throughout the drawings, like reference numerals designate likeor corresponding parts. While illustrative embodiments of the presentdisclosure have been described and illustrated above, it should beunderstood that these are exemplary of the disclosure and are not to beconsidered as limiting. Additions, deletions, substitutions, and othermodifications can be made without departing from the spirit or scope ofthe present disclosure. Accordingly, the present disclosure is not to beconsidered as limited by the foregoing description.

What is claimed is:
 1. A weatherproof switch cover comprising: a baseplate including top and bottom walls, a pair of side walls, an exteriorsurface and an open interior area, the exterior surface being secured toor integrally molded into the top and bottom walls and the pair of sidewalls, the exterior surface having an opening configured to align withan electrical switch; an actuator associated with the base plate andaccessible through the opening, the actuator being movable between afirst position and a second position, wherein when the actuator is inthe first position the actuator stays in the first position until theactuator is moved to the second position, and when actuator is in thesecond position the actuator stays in the second position until theactuator is moved to the first position; and a flexible weatherproofseal member between the actuator, the opening and the open interiorarea.
 2. The weatherproof switch cover of claim 1, wherein when theactuator is moved to the first position a first portion the flexibleweatherproof seal member flexes in a direction away from the actuatorand when the actuator is moved to the second position a second portionthe flexible weatherproof seal member flexes in a direction away fromthe actuator.
 3. The weatherproof switch cover of claim 1, furthercomprising a feedback mechanism providing tactile feedback to a userwhen the actuator is moved between the first and second positions. 4.The weatherproof switch cover of claim 1, wherein the actuator comprisesa rocker arm.
 5. The weatherproof switch cover of claim 1, wherein theflexible weatherproof seal member comprises a flexible membrane.
 6. Anelectrical kit comprising: an electrical box; and a weatherproof switchcover mountable to the electrical box, the weatherproof switch covercomprising: a base plate including top and bottom walls, a pair of sidewalls, an exterior surface and an open interior area, the exteriorsurface being secured to or integrally molded into the top and bottomwalls and the pair of side walls, the exterior surface having an openingconfigured to align with an opening in the electrical box; an actuatorassociated with the base plate and accessible through the opening, theactuator being movable between a first position and a second position,wherein when the actuator is in the first position the actuator stays inthe first position until the actuator is moved to the second position,and when actuator is in the second position the actuator stays in thesecond position until the actuator is moved to the first position; and aflexible weatherproof seal member between the actuator, the opening andthe open interior area.
 7. The electrical kit of claim 6, wherein whenthe actuator is moved to the first position a first portion the flexibleweatherproof seal member flexes in a direction away from the actuatorand when the actuator is moved to the second position a second portionthe flexible weatherproof seal member flexes in a direction away fromthe actuator.
 8. The electrical kit of claim 6, wherein the actuatorcomprises a rocker arm.
 9. The electrical kit of claim 6, wherein theflexible weatherproof seal member comprises a flexible membrane.
 10. Aweatherproof switch cover comprising: a base plate including top andbottom walls, a pair of side walls, an exterior surface and an openinterior area, the exterior surface being secured to or integrallymolded into the top and bottom walls and the pair of side walls, theexterior surface having an opening and at least one hole for attachingthe base plate to an electrical switch or an electrical box; an actuatoroperatively coupled to the base plate within the open interior area andaccessible through the opening, the actuator being movable between afirst position and a second position, wherein when the actuator is inthe first position the actuator stays in the first position until theactuator is moved to the second position, and when the actuator is inthe second position the actuator stays in the second position until theactuator is moved to the first position; and a flexible seal memberprovided within the open interior area, the flexible seal member betweenthe opening and the open interior area.
 11. The weatherproof switchcover of claim 10, wherein the actuator comprises a first finger thatpresses into a first nub provided in the flexible seal member when theactuator is moved to the first position, and a second finger thatpresses into a second nub provided in the flexible seal member when theactuator is moved to the second position.
 12. The weatherproof switchcover of claim 10, wherein the actuator comprises a first finger thatpresses into the flexible seal member when the actuator is moved to thefirst position, and a second finger that presses into the flexible sealmember when the actuator is moved to the second position.
 13. Theweatherproof switch cover of claim 10, wherein the actuator comprises arocker arm.
 14. The weatherproof switch cover of claim 10, wherein theflexible seal member comprises a flexible membrane.
 15. An electricalkit comprising: an electrical box; and a weatherproof switch covermountable to the electrical box, the weatherproof switch covercomprising: a base plate including top and bottom walls, a pair of sidewalls, an exterior surface and an open interior area, the exteriorsurface being secured to or integrally molded into the top and bottomwalls and the pair of side walls, the exterior surface having an openingand at least one hole for attaching the base plate to the electrical boxor an electrical switch mounted to the electrical box; an actuatoroperatively coupled to the base plate within the open interior area andaccessible through the opening, the actuator being movable between afirst position and a second position, wherein when the actuator is inthe first position the actuator stays in the first position until theactuator is moved to the second position, and when the actuator is inthe second position the actuator stays in the second position until theactuator is moved to the first position; and a flexible seal memberprovided within the open interior area, the flexible seal memberproviding a weatherproof seal between the opening and the open interiorarea.
 16. The electrical kit of claim 15, wherein the actuator comprisesat least one finger that presses into nubs provided in the flexible sealmember when the actuator is moved to the first position and when theactuator is moved to the second position.
 17. The electrical kit ofclaim 15, wherein the actuator comprises at least one finger thatpresses into the flexible seal member when the actuator is moved to thefirst position and when the actuator is moved to the second position.18. The electrical kit of claim 15, wherein the actuator comprises arocker arm.
 19. The electrical kit of claim 15, wherein the flexibleseal member comprises a flexible membrane.
 20. A weatherproof multi-gangcover comprising: a base plate including top and bottom walls, a pair ofside walls, an exterior surface and an open interior area, the exteriorsurface being secured to or integrally molded into the top and bottomwalls and the pair of side walls, the exterior surface having at leasttwo openings each configured to align with an electrical switch; atleast two actuators associated with the base plate and positioned withinthe open interior area, each actuator being accessible through one ofthe openings and movable between a first position and a second position,wherein when the actuator is in the first position the actuator stays inthe first position until the actuator is moved to the second position,and when actuator is in the second position the actuator stays in thesecond position until the actuator is moved to the first position; andat least one flexible weatherproof seal member between the at least twoactuators, the at least two openings and the open interior area.
 21. Aweatherproof multi-gang cover comprising: a base plate including top andbottom walls, a pair of side walls, an exterior surface and an openinterior area, the exterior surface being secured to or integrallymolded into the top and bottom walls and the pair of side walls, theexterior surface having at least two openings and at least one hole forattaching the base plate to an electrical switch or an electrical box;at least two actuators operatively coupled to the base plate within theopen interior area, each actuator being accessible through one of theopenings and movable between a first position and a second position,wherein when the actuator is in the first position the actuator stays inthe first position until the actuator is moved to the second position,and when the actuator is in the second position the actuator stays inthe second position until the actuator is moved to the first position;and at least one flexible seal member provided within the open interiorarea, the at least one flexible seal member providing a weatherproofseal between the at least two openings and the open interior area.